WO2006090058A1

WO2006090058A1 - Method for making a coil for a rotating electrical machine rotor

Info

Publication number: WO2006090058A1
Application number: PCT/FR2006/000394
Authority: WO
Inventors: Michel Aeschlimann
Original assignee: Valeo Equipements Electriques Moteur
Priority date: 2005-02-25
Filing date: 2006-02-22
Publication date: 2006-08-31
Also published as: US20080040912A1; JP2008532465A; FR2882613B1; FR2882613A1; US7818873B2

Abstract

The invention concerns a method for making an excitation coil (22) of a rotor (1) of a rotating electrical machine including: a step of winding at least one electrical conductor element (30), the winding forming, in superimposed layers, a horizontal and vertical juxtaposition of turns of the electrical conductor element; a step of impregnating to fill with a binder (34) interstices formed between adjacent turns. The invention is characterized in that the impregnating step is carried out during the step for winding of the electrical conductor element (30).

Description

METHOD FOR MANUFACTURING A DOBINE FOR A ROTOR OF A MACHINE

ELECTRIC ROTATING

Technical field of the invention

The present invention relates to a method for manufacturing an excitation winding of a rotor of a rotating electrical machine.

The invention finds applications in particular in the field of the automotive industry and, in particular, in the field of alternators and alternator-starters.

State of the art

The rotating electrical machine comprises a rotor and a stator on each of which can be realized an electric winding.

This rotating electrical machine can be an alternator that transforms a rotational movement of the rotor into an electric current. The electric machine can also be a motor that transforms an electric current, which passes through the rotor winding, into a rotational movement of the rotor. The machine can also be reversible and thus transform mechanical energy into electrical energy and vice versa.

A rotor conventionally comprises:

a magnetic core,

an electric winding which comprises a winding of at least one conductive element,

- A coil holder having at least one annular transverse flange serving in particular for winding at least one conductive element.

The winding is performed during a winding step of the conductive element which allows to form regularly distributed turns on the magnetic core. A winding therefore presents itself as a horizontal and vertical juxtaposition of turns, forming radially superposed conductive element layers. The conductive element has, in cross section, a generally round shape.

It may also be noted that the conductive element comprises a electrically conductive portion, for example, a copper wire and an electrically insulating portion, for example, an enamel layer surrounding the copper wire.

However, during the use of the rotating machine, because of the vibrations and under the effect of centrifugal force, the turns of the electrically conductive element move relative to each other and rub either between them or against at least one flange of the coil support. Thus, the enamel protecting the copper wire can be damaged. The short-circuits, which result, cause more or less quickly the putting out of use of the rotating machine.

In addition, there are gaps between adjacent turns of the electrical conductive element. These interstices are filled with air. However, during the operation of the electric machine, the turns are heated. Since the air present in the interstices is a thermal insulator, the evacuation of heat towards the outside of the winding is not optimized. The efficiency of the machine is thus reduced.

To avoid these drawbacks, document FR 1560304 discloses a method of manufacturing a winding of a rotor of a rotating electrical machine. This rotor comprises teeth belonging to polar wheels. After constituting a coil on a magnetic core by a winding step of at least one conductive element, it is filled with a binder, forming an impregnation means, existing interstices between adjacent turns. This binder is better thermal conductor than air. For this purpose, a dispensing head pours the binder, when the rotor is stopped, using the space between the two adjacent teeth. Then the rotor turns at an angle of 120 °, and the dispensing head pours the binder again. The binder is thus discharged at several points distributed around the periphery of the winding. This distribution is therefore carried out in several stages.

The method disclosed in this document does not satisfactorily fill all existing gaps between the adjacent turns of the electrical conductive element.

Indeed, the rotor being mounted with its pole wheels, the distributor can not approach the winding optimally. As a result, the payment of the binder can not be precise. There is thus a risk that the binder spills on areas of the rotor that should not normally receive it, such as teeth or pole wheels.

In addition, the distributor deposits the binder punctually on the periphery of the winding. Thus the gaps between the adjacent turns of the upper layers of the coil are not all filled uniformly. In addition, in the case where the density of the turns of the electrically conductive element in the coil is large, the binder can not reach the interstices existing between the adjacent turns of the lower layers of the coil.

Finally, the method, as presented in the state of the art, is not optimized in time since the binder is poured in several times on the winding.

Presentation of the invention

Also, a technical problem to be solved by the object of the present invention is to propose a method of manufacturing an excitation winding of a rotor, as well as an associated rotating electrical machine, which make it possible:

improving the filling with a binder of the interstices existing between the adjacent turns of the upper and lower layers of the winding,

to reduce the time of the manufacturing process,

- To fill the interstices in a simple and economical way.

A solution to the technical problem raised is according to a first object of the present invention a manufacturing method characterized in that the impregnation step takes place during the winding step of the electrical conductive element. Thanks to the invention, the interstices existing between the adjacent turns are filled with binder as and when the winding is carried out. Thus, the friction between the turns is avoided and the heat dissipation at the winding is improved so that the magnetic performance of the rotor is increased. According to preferred non-limiting embodiments, the method which is the subject of the invention has the additional characteristics, taken separately or in combination, set out below.

During the impregnation step, the flow rate of the binder is controlled. The binder is a varnish in liquid or semi-liquid form.

The binder is deposited on a part of the length of the conductive element by distributor means.

The binder is deposited over the entire length of the conductive element by distributor means.

The binder becomes solid once the winding step is complete.

The binder is solidified by heating means.

According to a second object of the invention, a rotating electrical machine, in particular for a motor vehicle, provided with a rotor comprising an excitation winding is characterized in that the winding is produced according to the method of the invention.

This is particularly advantageous in the case of a rotary electric machine with a claw rotor carrying permanent magnets.

Brief description of the Figures

Fig. 1 is a partial view in elevation and partially in axial section of a claw rotor carrying permanent magnets, said rotor comprising a winding manufactured according to the method of the invention. Fig. 2 is a schematic representation of the implementation of an impregnation method, according to a first non-limiting embodiment of the invention,

Fig. 3 is a schematic representation of the implementation of an impregnation method, according to a second non-limiting embodiment of the invention and,

Fig. 4 is a schematic representation of the implementation of an impregnation method, according to a third non-limiting embodiment of the invention. DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

In the following description, there is shown an example of an electric machine. It is shown in FIG. 1 a rotor 1 belonging to a claw-type alternator carrying permanent magnets.

In the remainder of the description, use will be made of an X-X axial orientation from front to back which corresponds to a left-to-right orientation by considering FIG. 1.

The rotor 1 has a drive shaft 20 which allows the mounting of said rotor 1 in rotation in a housing (not shown) of the alternator. This housing carries bearings centrally, one of which is shown in FIG. 1, for the rotational mounting of the shaft.

A substantially cylindrical annular core 21 is rotatably mounted on the central portion of the X-X axis of rotation drive shaft 20.

There is further provided a coil carrier of electrically insulating plastic material carried by the outer periphery of the core.

In one embodiment, the coil carrier has a single annular transverse flange. A layer of electrically insulating material is placed on the outer periphery of the core. The winding of the electrically conductive element is therefore performed on said layer. Note that this layer is independent of the coil support and that, by the winding step, it is interposed radially between the radially inner turns of the coil and the core. In another embodiment, the coil support may comprise a single annular rear transverse flange and also an axially oriented skirt. In this case, the axially oriented skirt extends forwardly from the inner edge of the rear face of the flange.

In another embodiment, the coil support comprises an annular front transverse flange and an annular rear transverse flange and an axially oriented annular skirt connecting the two flanges.

For these last two embodiments, once the winding step of the electrically conductive element performed on the coil support, the latter is mounted on the magnetic core. The axially oriented skirt is thus interposed radially between the radially inner turns of the coil and the magnetic core and takes over, in addition, the function of the layer of electrically insulating material. Note that the coil holder can be mounted, for example, by force on the magnetic core.

Note also that the magnetic core is a substantially cylindrical annular element independent of the two pole wheels.

Alternatively, the magnetic core may be in two parts each of which is integral with the inner face of a corresponding pole wheel.

In the example illustrated in FIG. 1, the winding of the rotor of the rotating electrical machine is carried out in a plastic bobbin holder which makes it possible to receive and guide the conductive element during its winding and which is fixed, for example, by press fit on a magnetic core 21. The coil carrier has a U-shaped cross-section. It comprises an annular front transverse flange 25a, an annular rear transverse flange 25b and an axially oriented annular skirt 25c connecting the two flanges. The core 21 is here in one piece. It is clamped axially between the two pole wheels 23a, 23b.

Each of the pole wheels 23a, 23b comprises an annular plate (17) carrying at its outer periphery claws each comprising a transverse portion 19 rooting flange prolonged by a tooth 24a, 24b of axial orientation. The teeth 24a, 24b are, for example, six in number for each of the pole wheels 23a, 23b and distributed angularly in a regular manner about the axis XX common to the pole wheels 23a, 23b and to the drive shaft 20 .

In this embodiment, each of the teeth 24a, 24b of a pole wheel 23a, 23b extends axially towards the pole wheel 23a, 23b vis-à-vis, so that the teeth 24a, 24b are interlocked with each other. in the others and so as to delimit radially, with the outer cylindrical surface 18 of the core 21, a space in which a winding 22 is arranged.

The electrical winding 22 is made by winding an electrical conducting element 30 in turns so as to form conductive element layers when moving radially from the inside to the outside in the winding.

The conductive element comprises an electrically conductive portion 36, for example, a copper wire surrounded by a single electrically insulating portion 31, for example, an enamel layer. The conductive element has, in cross section, a generally round shape. The winding is carried out by winding the conductive element 30 so as to form layers Ci containing turns Sj. The index i varies from 1 to n, where n is the maximum number of layers of the winding. The index j varies from 1 to m, where m is the maximum number of turns per layer. The layers are thus superimposed radially. The turns belonging to the same layer are aligned axially.

In the following description, the first layer of the conductive element, which will be designated by the reference "C1", is the radially inner layer of the coil 22. The first turn of the layer Ci, which will be designated by the reference S1, corresponds to the turn which will be the first wound for a given layer. Depending on the layers, the first turn will alternately be the turn nearest the rear annular flange 25b, or the closest to the front annular flange 25a. The rear transverse flange 25b comprises a first means 27 for fixing the starting end of the electric conductive element 30.

The rear transverse flange 25b further comprises a second means (not shown), substantially diametrically opposed to the first means 27, for fixing the end of the electrical conductive element.

The starting end and the end end of the electrical conducting element are intended to be electrically connected to a source of electric current during operation of the rotor 1.

The winding of the conductive element 30 is carried out according to the following steps. Firstly, the electrical conducting element is fixed on the coil support by the first means 27. The winding is then made by the combination of two movements: a rotation of the core 21 about its axis XX and an axial translation, the core with respect to the conductive element, or the conductive element with respect to the core. Thus, the first turn S1 of the conductive element, belonging to the first layer C1 of the coil, is wound on the axially oriented skirt 25c, from the rear flange 25b.

The second turn S2 of the conductive element, belonging to the first layer C1 of the coil, is wound on the axial skirt next to the first turn S1, for example, by axial displacement of the core 21 and so on.

The winding step ends with the fixing of the terminal end of the electrically conductive element on the second fixing means.

The winding thus forms a horizontal and vertical juxtaposition of turns separated by interstices 33.

During the winding step, the impregnation step is performed. Thus, with the binder, as the winding progresses, the interstices 33 existing between the adjacent turns of an electrically conductive element 30 and the interstices 33 between the turns and the flanges 25a, 25b of the support are filled. of coil.

The binder 34 is chosen so that it can fill the interstices easily. The binder is, for example, a varnish which may be in liquid or semi-liquid form such as a gel.

Thus, a first embodiment is described and shown in FIG. 2.

The first turn S1 of the conductive element 30, belonging to the first layer C1, is wound as close to the rear flange 25b. The following turns (S2, ...) are progressively offset axially forward, that is to say in the direction of the arrow F1, to form the first layer C1 of the coil on the skirt 25c.

The first turn S1 of the conductive element 30, belonging to the second layer C2, is wound closer to the front flange 25a. The following turns are progressively shifted axially rearward towards the rear flange, that is to say in the direction of the arrow F2, to form the second layer of the winding.

The winding of the conductive element 30 continues in a similar manner, the turns of each layer alternately shifting forward or backward from one layer to another.

During the constitution of the different layers, a dispensing means 35 discharges a binder once the coil inserted in its layer. Thus, the interstices are filled as they are created.

However, according to a second embodiment, shown in FIG.

3, it is also possible that the dispensing means 35 come pouring the binder on the turn, during the winding step, but before it is inserted into its layer. Thus, the interstices fill up as soon as the spire is inserted. In addition, according to a third embodiment, shown in FIG. 4, it is also possible for the distributor means 35 to pour the binder on the lower layer Ci, during the winding of the turns of the layer which is greater than Ci + 1. Thus, as soon as the binder is deposited, it is instantly crushed by the coil which allows better filling the interstices.

Finally, according to a fourth embodiment, not shown, it is also possible for the distributor means 35 to pour the binder over the entire width of the coil support during the winding of the turns forming successive layers. The dispensing means 35 will therefore be of suitable dimensions and / or at an appropriate distance from the winding to pour the binder over several turns at the same time.

In all four embodiments, the distributor means 35 preferably allows the binder to be deposited by gravity. The dispensing means may be for example a nozzle connected to a reservoir (not shown) of binder.

The nozzle can follow the offset of the turns during the constitution of the successive layers or be immobile.

The nozzle thus makes it possible to deposit the binder over the entire length of the conductive element 30.

The set of interstices 33, existing between the adjacent turns and the turns and the coil support 25a, 25b, 25c, is thus filled by the binder. The last layer of the coil is also covered with this binder.

For the various embodiments, it is also possible to provide control means (not shown) for the flow rate of the binder in the nozzle during the impregnation step. These means may be, for example, clamp type or valve. Thus, it is possible to select, for the two embodiments, the winding layers for which it is desired to fill the existing interstices 33, by depositing the binder on a part of the length of the electrically conductive element 30. For example, it is possible to come impregnate only the lower layers. These layers are the most difficult to reach, by a conventional impregnation process, because of the density of the turns. For the upper layers, the interstices will subsequently be filled by another conventional method of depositing a binder. In addition to filling the interstices, this process will cover the last layer of binder. The conventional method may be, for example, that described in the state of the art.

In addition, controlling the removal of the binder avoids covering parts of the driver that do not need to be. So, lorqu'on begins or ends the winding step by fixing the end of the electrical conductive element on the first fastening means 27 or the second fastening means, it is avoided to deposit binder. This will limit the consumption of this binder while improving the cleanliness of the winding operation.

In addition, the use of control means makes it possible to ensure that the interstices will be filled by the right amount of binder.

Indeed, if the amount of binder spilled is insufficient, the turns may rub against each other. In addition, the evacuation of heat at the winding will be less efficient because of the presence of air bubbles in the interstices.

Conversely, if the amount of binder poured is too large, there is likely to be a lot of binder projection during winding turns.

The binder, once the winding step is complete, becomes solid. The solidification can take place, for example, by heating means such as an oven. Thus the adjacent turns are immobilized relative to each other and with respect to the coil support 25a, 25b, 25c. The friction between the turns is thus avoided and the heat dissipation at the winding is improved so that the magnetic performance of the rotor during operation of the machine is increased.

It should be noted that the heating means can be used at once according to whether only the method of the invention is used or that this method is combined with a conventional impregnation process. The heating means can also be used several times in the case where this process is combined with a conventional impregnation process.

The invention therefore makes it possible to manufacture an excitation winding of a rotor 1 of a rotating electrical machine by improving the filling with a binder 34 of the existing gaps 33 between adjacent turns of the upper and lower layers of the coil 22. The binder 34 thus penetrates the core of the winding 22 because the impregnation step takes place during the winding step.

Moreover, the binder 34 is controlled and more precise. Only the winding 22 receives it. This avoids projections of the binder on areas of the rotor, such as the pole wheels, which should not be covered at this time by said binder. The use of scraping or stripping operations on these areas of the rotor is thus avoided. We can thus, for example, perform quickly a welding operation of a fan, on one or both polar wheels.

Finally, this method is more efficient in terms of time saving. In fact, gaps are filled during the winding step of the electrical conductive element 30.

Once the winding step is complete, the assembly comprising the winding 22, the coil support 25a, 25b, 25c, the core 21 between the two pole wheels 23a, 23b is placed. It should be noted that this assembly can be done before or after the use of the heating means on the winding.

In the case of permanent magnet claw rotors, magnets 28 are placed in the teeth 24a, 24b.

The magnets 28 are housed in grooves 29 present in the lateral faces of two respective teeth 24a, 24b. The grooving operation takes place once the teeth are placed relative to each other, so once the assembly comprising the coil 22, the coil support 25a, 25b, 25c, the core 21, is clamped axially between the two pole wheels 23a, 23b.

Note that during this grooving, there is a risk of chip projection and thus degradation of the coil 22 by these chips.

The varnish, present on the last upper layer of the coil and which is in a solid form, thus acts as a means of protecting the winding against chips.

Thus, this process, filling gaps during the winding step of a copper wire surrounded by a single layer of enamel, allows a reduced manufacturing time without additional steps and this simply and economically . In addition, with this type of enamelled copper wire, the diameter of the conductive element is limited, the volume of the interstices thus created and therefore the need for binder is reduced.

The present description is not limited to the embodiments described above.

The invention applies to any type of rotating electrical machine such as an alternator, an electromagnetic retarder or an electromagnetic coupler with eddy currents and also to any type of reversible rotating electrical machine such as an alternator-starter.

Claims

A method of manufacturing a coil (22) for exciting a rotor (1) of a rotating electric machine comprising:

a step of winding at least one electrical conducting element (30), the winding forming, in superimposed layers, a horizontal and vertical juxtaposition of turns of the electrically conductive element,

an impregnation stage intended to fill with a binder (34) interstices (33) formed between adjacent turns, characterized in that the impregnation step takes place during the winding step of the electrically conductive element (30).

2. Method according to claim 1 characterized in that during the impregnating step the flow rate of the binder is controlled.

3. Method according to claim 1 characterized in that the binder (34) is a varnish in a liquid or semi-liquid form.

4. Method according to claim 1 characterized in that the binder (34) is deposited on a portion of the length of the conductive member (30) by distributor means (35).

5. Method according to claim 1 characterized in that the binder (34) is deposited over the entire length of the conductive member (30) by distributor means (35).

6. Method according to claim 1 characterized in that the binder (34) becomes solid once the winding step is complete.

7. Process according to claim 6, characterized in that the binder (34) is solidified by heating means.

8. Rotating electrical machine with a rotor comprising an excitation winding characterized in that said winding is produced according to the method of claim 1.

9. rotary electric machine according to claim 8 characterized in that the rotor is a claw rotor carrying permanent magnets.